Komatsu HM400-2 Articulated Dump Truck Service Manual
1,515 pages · Publication SEN00239-20
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- Models
- HM400-2
- Serial coverage
- 2001 and up
- Manual type
- Service Manual
- Pages
- 1,515
- Publication
- SEN00239-20
- Condition
- Brand new
What's inside
From the manual's own table of contents: 223 sections, 459 entries. See sample pages (PDF, 774 KB)
Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification drawings
Specifications
Weight table
Fuel, coolant and lubricants
Radiator, oil cooler, aftercooler
Output shaft
Power train skeleton
Torque converter and transmission hydraulic piping
Brake cooling oil control valve (BCV)
Power train pump
Torque converter
Transmission
Transmission control valve
Show all 223 sections
ECMV
Main relief, torque converter relief valve
Drive shaft
Axle
Differential
Limited slip differential
Final drive
Steering column
Brake piping
Brake valve
Accumulator charge valve
Accumulator
Slack adjuster
Brake42 topics
- Proportional reducing valve
- Brake system tank
- Parking brake
- Parking brake solenoid valve
- Suspension
- Suspension cylinder
- Oscillation hitch
- Steering, hoist oil pressure piping diagram
- Dump body control
- Hydraulic tank and filter
- Flow amp valve
- Steering valve
- Steering cylinder
- Hoist valve
- Dump control valve (EPC valve)
- Pilot check valve
- Hoist cylinder
- Hydraulic pump
- ROPS cab
- Cab tilt
- Air conditioner
- Rear view monitor
- Controller related
- Machine monitor system
- Automatic shift control system
- Transmission controller
- Retarder control system
- Auto emergency steering system
- Battery disconnector switch
- Emergency engine stop switch
- Dump control lever
- Playload meter (Card type)
- Sensors, switches
- KOMTRAX terminal system (if equipped)
- Standard value table for engine
- Standard value table for chassis
- Tools for testing, adjusting, and troubleshooting
- Measuring engine speed
- Testing intake air pressure (boost pressure)
- Testing exhaust temperature
- Testing exhaust gas color
- Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Testing EGR valve and bypass valve drive oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing fuel pressure
Testing fuel return and leakage amount
Bleeding air from fuel circuit
Testing the fuel circuit for leakage
Testing and adjusting fan belt tension
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Adjusting the body mount
Testing torque converter stall speed
Testing power train oil pressure
Testing and adjusting of differential lock oil pressure (differential lock spec.)
Adjusting transmission speed sensor
Testing and adjusting brake oil pressure
for charging accumulator with nitrogen gas
Testing brake performance
Bleeding air from brake circuit
Testing wear of wheel brake disc
Testing the parking brake pad wear
Emergency release of the parking brake
Testing and adjusting steering circuit oil pressure
Testing and adjusting suspension cylinder
Method of tilting cab up
Testing and adjusting dump circuit oil pressure
Adjusting body positioner sensor
Adjusting length of spring in body heating spherical joint
Handling of voltage circuit of engine controller
Adjusting transmission controller
Method for emergency escape at electrical system failure
Setting and adjusting various equipments
Special function of machine monitor
How to start operation of KOMTRAX terminal
Lamp display of KOMTRAX terminal
Pm Clinic check sheet
Initial setting of payload meter
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and procedures for troubleshooting
Connection table for connector pin numbers
T-branch box and T-branch adapter table
Troubleshooting by failure code, General
Failure codes table
Before troubleshooting by failure code
Information in troubleshooting table54 topics
- Troubleshooting by failure code, Part 1
- Failure code [1500L0] Double engagement
- Failure code [15B0NX] Transmission oil filter: Clogged
- Failure code [15F0KM] R o F shifting abuse 1
- Failure code [15F0MB] R o F shifting abuse 2
- Failure code [15F7KM] Transmission forward clutch abuse
- Failure code [15G0MW] Trouble in reverse clutch system (Slip)
- Failure code [15G7KM] Transmission reverse clutch abuse
- Failure code [15H0MW] Trouble in Hi clutch system (Slip)
- Failure code [15J0MW] Trouble in Lo clutch system (Slip)
- Failure code [15K0MW] Trouble in 1st clutch system (Slip)
- Failure code [15L0MW] Trouble in 2nd clutch system (Slip)
- Failure code [15M0MW] Trouble in 3rd clutch system (Slip)
- Failure code [15SBL1] Trouble in reverse clutch pressure control valve
- Failure code [15SBMA] Trouble in reverse clutch pressure control valve
- Failure code [15SCL1] Trouble in Hi clutch pressure control valve
- Failure code [15SCMA] Trouble in Hi clutch pressure control valve
- Failure code [15SDL1] Trouble in Lo clutch pressure control valve
- Failure code [15SDMA] Trouble in Lo clutch pressure control valve
- Failure code [15SEL1] Trouble in 1st clutch pressure control valve
- Failure code [15SEMA] Trouble in 1st clutch pressure control valve
- Failure code [15SFL1] Trouble in 2nd clutch pressure control valve
- Failure code [15SFMA] Trouble in 2nd clutch pressure control valve
- Failure code [15SGL1] Trouble in 3rd clutch pressure control valve
- Failure code [15SGMA] Trouble in 3rd clutch pressure control valve
- Failure code [15SJMA] Trouble in lockup clutch pressure control valve
- Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve
- Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2
- Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1
- Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2
- Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1
- Failure code [2C4MNX] Clogging of retarder cooling oil filter
- Failure code [2F00KM] Dragging of parking brake
- Failure code [2G42ZG] Lowering of accumulator oil pressure (front)
- Failure code [2G43ZG] Lowering of accumulator oil pressure (rear)
- Failure code [989A00] Operation of engine overrun prevention system
- Failure code [989D00] Rear section tipping over alarm (Raising operation on slope)
- Failure code [A570NX] Clogging of engine oil filter
- Failure code [AA10NX] Clogging of air cleaner
- Failure code [AB00MA] Trouble in battery charge circuit
- Failure code [B@BAZG] Lowering of engine oil pressure
- Failure code [B@BAZK] Lowering of engine oil level
- Failure code [B@BCNS] Overheating of engine
- Failure code [B@BCZK] Lowering of coolant level
- Failure code [B@BFZK] Lowering of fuel level
- Failure code [B@C6NS] Overheating of brake cooling oil (front)
- Failure code [B@C7NS] Overheating of brake cooling oil (rear)
- Failure code [B@C8NS] Overheating of brake cooling oil (center)
- Failure code [B@CENS] Overheating of torque converter oil
- Failure code [B@JANS] Overheating of steering oil
- Failure code [CA111] Trouble in engine controller
- Failure code [CA115] Trouble in engine Ne and Bkup speed sensors
- Failure code [CA122] Abnormally high charge pressure
- Failure code [CA123] Abnormally low charge pressure
Failure code [CA131] Abnormally high throttle sensor signal
Failure code [CA132] Abnormally low throttle sensor signal
Failure code [CA135] Abnormally high engine oil pressure
Failure code [CA141] Abnormally low engine oil pressure
Failure code [CA144] Abnormally high coolant temperature
Failure code [CA145] Abnormally low coolant temperature
Failure code [CA153] Abnormally high charge temperature
Failure code [CA154] Abnormally low charge temperature
Failure code [CA187] Abnormally low voltage in sensor power supply 2
Failure code [CA221] Abnormally high ambient pressure
Failure code [CA222] Abnormally low ambient pressure
Failure code [CA227] Abnormally high voltage in sensor power supply 2
Failure code [CA234] Engine overspeed
Failure code [CA238] Trouble in Ne speed sensor power supply
Failure code [CA263] Abnormally high fuel temperature
Failure code [CA265] Abnormally low fuel temperature
Failure code [CA271] Short circuit in PCV1
Failure code [CA272] Disconnection in PCV1
Failure code [CA273] Short circuit in PCV2
Failure code [CA274] Disconnection in PCV2
Failure code [CA322] Disconnection or short circuit in injector #1 (L #1)
Failure code [CA323] Disconnection or short circuit in injector #5 (L #5)
Failure code [CA324] Disconnection or short circuit in injector #3 (L #3)
Failure code [CA325] Disconnection or short circuit in injector #6 (L #6)
Failure code [CA331] Disconnection or short circuit in injector #2 (L #2)
Failure code [CA332] Disconnection or short circuit in injector #4 (L #4)
Failure code [CA342] Matching error in engine controller data
Failure code [CA351] Trouble in injector drive circuit
Failure code [CA352] Abnormally low voltage in sensor power supply 1
Failure code [CA386] Abnormally high voltage in sensor power supply 1
Failure code [CA431] Trouble in idle validation switch
Failure code [CA432] Trouble in idle validation process
Failure code [CA441] Abnormally low voltage in power supply
Failure code [CA442] Abnormally high voltage in power supply
Failure code [CA449] Abnormally high common rail pressure 2
Failure code [CA451] Abnormally high common rail pressure
Failure code [CA452] Abnormally low common rail pressure
Failure code [CA553] Abnormally high common rail pressure 1
Failure code [CA554] In-range error in common rail pressure sensor
Failure code [CA559] Supply pump low pressure 1
Failure code [CA689] Trouble in engine Ne speed sensor
Failure code [CA731] Phase error in engine Bkup speed sensor
Failure code [CA757] Loss of all data in engine controller
Failure code [CA778] Trouble in engine Bkup speed sensor
Failure code [CA1228] Trouble in EGR valve servo 1
Failure code [CA1625] Trouble in EGR valve servo 2
Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit
Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit
Failure code [CA1628] Trouble in bypass valve servo 1
Failure code [CA1629] Trouble in bypass valve servo 2
Failure code [CA1631] Abnormally high signal in bypass valve lift sensor
Failure code [CA1632] Abnormally low signal in bypass valve lift sensor
Failure code [CA1633] Trouble in KOMNET
Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor
Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor
Failure code [CA2185] Abnormally high voltage in throttle sensor power supply
Failure code [CA2186] Abnormally low voltage in throttle sensor power supply53 topics
- Failure code [CA2249] Low pressure in supply pump 2
- Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor
- Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor
- Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit
- Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit
- Failure code [CA2555] Disconnection in intake air heater relay
- Failure code [CA2556] Short circuit in intake air heater relay
- Failure code [DAF9KM] Wrong connection of connector
- Failure code [DAFRKR] Trouble in CAN communication (machine monitor)
- Failure code [DAQ0KK] Lowering of source voltage
- Failure code [DAQ0KT] Trouble in non-volatile memory
- Failure code [DAQ2KK] Trouble in solenoid power supply system
- Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller)
- Failure code [DAQRKR] Trouble in CAN communication (Transmission controller)
- Failure code [DAQRMA] Disagreement of option setting (Transmission controller)
- Failure code [DB10KT] Trouble in non-volatile memory
- Failure code [DB12KK] Trouble in solenoid power supply system
- Failure code [DB13KK] Lowering of battery direct voltage
- Failure code [DB19KQ] Disagreement of model selection (Retarder controller)
- Failure code [DB1QMA] Disagreement of option setting (Retarder controller)
- Failure code [DB1RKR] Trouble in CAN communication (Retarder controller)
- Failure code [DB2RKR] Trouble in CAN communication (Engine controller)
- Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal
- Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve
- Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve
- Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve
- Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve
- Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve
- Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve
- Failure code [DF10KA] Input of no lever signals
- Failure code [DF10KB] Input of multiple lever signals
- Failure code [DGF1KX] Transmission oil temperature out of range
- Failure code [DGR2KZ] Ground fault in brake oil temperature sensor (rear)
- Failure code [DGR2L8] Disconnection in brake oil temperature sensor (rear)
- Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center)
- Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center)
- Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front)
- Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front)
- Failure code [DGR6KX] Steering oil temperature out of range
- Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system
- pressure sensor system
- Failure code [DHT5L6] Trouble in torque converter oil pressure sensor
- Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system
- Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system
- Failure code [DJF1KA] Disconnection in fuel level sensor system
- Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS
- Failure code [DK52KX] Trouble in dump lever potentiometer 1
- Failure code [DK53L8] Trouble in dump lever potentiometer 2
- Failure code [DK54KX] Trouble in dump positioner sensor
- Failure code [DKH0KX] Pitch angle sensor signal out of range
- Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system
- Failure code [DLF1LC] Trouble in transmission input shaft speed sensor
- system
Failure code [DLF4KA] Disconnection in transmission differential speed sensor system
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system
Failure code [DV00KB] Short circuit in buzzer output circuit
Failure code [DW73KZ] Trouble in dump selector valve output system
Failure code [DW78KZ] Trouble in rear wheel BCV command output system
Failure code [DW79KZ] Trouble in front wheel BCV command output system
valve 1
pressure reducing valve
valve 2
Troubleshooting by failure code, Part 7
Failure code [DX13KA] Disconnection in output circuit of dump EPC valve
Failure code [DX13KB] Ground fault in output circuit of dump EPC valve
Failure code [DX13KY] Hot short in output circuit of dump EPC valve
Failure code [DX14KZ] Trouble in rear wheel differential lock command output system
Failure code [DX15KZ] Trouble in front wheel differential lock command output system1 topic
- solenoid
Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid
Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid
Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid
Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid
Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve
Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve
Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid
Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve
Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve
Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid
Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve
Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve
Troubleshooting by failure code, Part 8
Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid51 topics
- Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve
- Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve
- Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid
- Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve
- Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve
- Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid
- Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve
- Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve
- Before troubleshooting for electrical system
- Information in troubleshooting table
- Engine does not start (Starting motor does not turn)
- Auto preheater does not operate
- When starting switch is turned ON, machine monitor displays nothing
- When starting switch is turned OFF, machine monitor cannot be operated
- Alarm buzzer does not stop sounding
- display section
- Display of character display section cannot be changed
- Power mode selection function does not operate normally
- AISS function does not operate normally
- (Differential lock-up specification)
- Interaxle differential lock-up function does not operate normally
- Display of seat belt caution lamp is abnormal
- Turn signal lamps and pilot lamps do not operate normally
- Night lighting is abnormal
- Backup lamp and backup buzzer operate abnormally
- Emergency steering system does not operate
- Air conditioner does not operate normally
- Troubleshooting of hydraulic and mechanical system (H-mode)
- Machine does not start
- Travel is not smooth (Machine hunts)
- Lockup is not reset
- Start shock and gear shift shock are abnormally large
- Gear is not shifted up
- Travel speed or power is low
- Start and gearshift time lag is large
- Torque converter oil temperature is high
- Torque converter oil temperature is low
- Front brake does not work fully
- Center brake does not work fully
- Rear brake does not work fully
- Steering wheel is heavy
- Steering wheel does not move
- Steering wheel waggle
- Dump body raising speed is low
- Dump body does not move
- Hydraulic drift of dump body is large
- Method of using troubleshooting chart
- Starting performance of engine is poor
- Engine does not start
- Engine does not pick up smoothly
- Engine stops during operation
Engine does not rotate smoothly
Engine lack output (or lacks power)
Exhaust gas is black (incomplete combustion)
Oil consumption is excessive (or exhaust gas is blue)
Oil becomes dirty quickly
Fuel consumption is excessive
Oil is in coolant (or coolant spurts back or coolant level goes down)
Oil pressure drops
Oil level rises (Entry of coolant or fuel)
Coolant temperature becomes too high (Overheating)
Abnormal noise is made
Vibration is excessive
How to read this manual
List of adhesives
Special tool list
Sketches of special tools
Removal and installation of fuel supply pump
Removal and installation of engine assembly
Removal and installation of cylinder head assembly
Removal and installation of fuel injector assembly
Removal and installation of radiator assembly
Removal and installation of cooling assembly
Removal and installation of aftercooler
Removal and installation of engine front seal
Removal and installation of engine rear seal
Replacement procedure of exhaust pipe fire prevention cover
Removal and installation of output shaft assembly
Disassembly and assembly of output shaft assembly
Removal and installation of transmission and front differential assembly
Disconnection and coupling of front differential and transmission
Disassembly and assembly of torque converter assembly
Disassembly and assembly of transmission assembly
Disassembly and assembly of front differential assembly
Removal and installation of center differential assembly
Disassembly and assembly of center differential assembly
Removal and installation of rear differential assembly
Disassembly and assembly of rear differential assembly
Removal and installation of front final drive and brake assembly
Disassembly and assembly of front final drive and brake assembly
Removal and installation of center final drive and brake assembly
Disassembly and assembly of center final drive and plate assembly
Removal and installation of rear final drive and brake assembly
Disassembly and assembly of rear final drive and brake assembly
Removal and installation of center axle assembly
Removal and installation of rear axle assembly
Removal and installation of front suspension cylinder assembly
Removal and installation of rear suspension cylinder assembly
Disassembly and assembly of front and rear suspension cylinder assembly35 topics
- Removal and installation of equalizer bar assembly
- Removal and installation of front wheel assembly
- Removal and installation of rear front wheel assembly
- Removal and installation of rear rear wheel assembly
- Removal and installation of hitch frame assembly
- Disassembly and assembly of hitch frame
- Removal and installation of body assembly
- Disassembly and assembly of steering valve
- Removal and installation of flow amplifier valve assembly
- Removal and installation of hoist valve assembly
- Disassembly and assembly of hoist valve assembly
- Disassembly and assembly of steering cylinder assembly
- Disassembly and assembly of hoist cylinder assembly
- Removal and installation of operator's cab
- Removal and installation of operator's cab glass (Stuck glass)
- Disassembly and assembly of operator’s seat assembly
- Removal and installation of air conditioner unit assembly
- Removal and installation of retarder controller assembly
- Removal and installation of transmission controller assembly
- Removal and installation of engine controller assembly
- Power train hydraulic circuit diagram
- Steering and hoist hydraulic circuit diagram
- Brake hydraulic circuit diagram
- Brake cooling hydraulic circuit diagram
- Differential lock hydraulic circuit diagram
- Electrical circuit diagram for inside cab (1/4)
- Electrical circuit diagram for inside cab (2/4)
- Electrical circuit diagram for inside cab (3/4)
- Electrical circuit diagram for inside cab (4/4)
- Electrical circuit diagram for outside cab (1/4)
- Electrical circuit diagram for outside cab (2/4)
- Electrical circuit diagram for outside cab (3/4)
- Electrical circuit diagram for outside cab (4/4)
- Electrical circuit diagram for payload meter
- Connectors table and arrangement drawing
Inside this manual
Real pages from this service manual (1,515 pages). Open the sample pages (PDF, 774 KB)
- Troubleshooting, page 776: Failure code [CA432] Trouble in idle validation process
- Diagram, page 914: Failure code [DLF2LC] Disconnection in transmission intermediate
- Specifications, page 1,420: 50 Disassembly and assembly
- Foldout diagram: Electrical circuit diagram for inside cab (2/4)
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the HM400-2 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,515 pages
Quantity one is the manual described above.
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Other editions and similar models
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